FinFET semiconductor structures and methods of fabricating same

ABSTRACT

The invention provides a method of forming a semiconductor structure, which include: providing an intermediate semiconductor structure having semiconductor substrate, a fin having an EG oxide layer in contact with at least a portion of the fin, and a gate stack disposed over a portion of the fin; forming a silicon nitride layer over portions of the fin that are not located under the gate stack; and after forming the silicon nitride layer, performing one or more ion implantation steps on the intermediate semiconductor structure. The invention also provides a method of forming a semiconductor structure including: providing an intermediate semiconductor structure having a semiconductor substrate, a fin having an EG oxide layer in contact with at least a portion of the fin, and a gate material disposed over the fin; forming, over the fin and gate material of the intermediate semiconductor structure, a gate stack hardmask including an oxide layer; forming a silicon nitride barrier layer on the oxide layer of the gate stack hardmask; performing one or more gate stack hardmask patterning steps; removing the EG oxide layer from portions of the fin that are not located under the gate; and subsequent to removing the EG oxide layer from portions of the fin that are not located under the gate, performing one or more ion implantation steps.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 14/519,215, filed on Oct. 21, 2014, which claims priority to U.S.Provisional Application No. 61/896,989, filed Oct. 29, 2013. The entiredisclosures of each of the prior applications are hereby incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention generally relates to semiconductor structures andmethods of fabricating semiconductor structures, and more particularly,to methods of forming semiconductor structures using a protectivesilicon nitride layer and optionally including an EG oxide removal forpost-PC implantation improvements.

BACKGROUND OF THE INVENTION

In contrast to traditional planar metal-oxide-semiconductor field-effecttransistors (MOSFETs), which are fabricated using conventionallithographic fabrication methods, nonplanar field-effect transistors(FETs) incorporate various vertical transistor structures, and typicallyinclude two or more gate structures formed in parallel. One suchsemiconductor structure is the “FinFET,” which takes its name from themultiple thin “fins” that are used to form the respective gate channels,and which are typically on the order of tens of nanometers in width.

More particularly, referring to the exemplary prior art semiconductorstructure shown in FIG. 1, a finFET 10 generally includes two or moreparallel silicon fin structures (or simply “fins”) 12. The fins aretypically formed on a semiconductor substrate 14 (FIG. 2) with the finstructures extending between a common drain electrode and a commonsource electrode (not shown). A conductive gate structure 16 “wrapsaround” three sides of fins 12, and is separated from the fins by astandard gate oxide layer 18. Fins 12 may be suitably doped to producethe desired FET polarity, as is known in the art, such that a gatechannel is formed within the near surface of the fins adjacent to gateoxide 18.

FIG. 2 illustrates, in cross-section, a conventional semiconductorsubstrate 14 including a support substrate 20, a silicon oxide layer 22,and a silicon-comprising material layer 24 overlying the silicon oxidelayer. The silicon-comprising material from which the fin structures areformed and the silicon oxide layer form a silicon on insulator (SOI)structure 26 that, in turn, is supported by the support substrate 20.Fins may be formed using any conventional process, including but notlimited to, conventional photolithographic and anisotropic etchingprocesses (e.g. reactive ion etching (RIE) or the like). After formationand cleaning of the fins, FinFET processing steps may include formingthe gate structure(s) 16, ion implantation, and source/drain (S/D)epitaxy modules.

Unfortunately, semiconductor structure processing steps performedsubsequent to fin formation can create defects in the fins, and/or cancause portions of the fins to become eroded. These defects and erodedfins can compromise the performance of semiconductor devices in whichthey are ultimately used.

Thus, a need exists for improved semiconductor structures and methods ofmaking the same, which allow for the integrity of the fin structures tobe better preserved during semiconductor fabrication. Other desirablefeatures and characteristics of the present invention will becomeapparent from the following detailed description of the invention andthe appended claims, taken in conjunction with the accompanying drawingsand this background of the invention.

While certain aspects of conventional technologies have been discussedto facilitate disclosure of the invention, Applicant in no way disclaimsthese technical aspects, and it is contemplated that the claimedinvention may encompass one or more of the conventional technicalaspects discussed herein.

In this specification, where an act or item of knowledge is referred toor discussed, this reference or discussion is not an admission that theact or item of knowledge or any combination thereof was, at the prioritydate, publicly available, known to the public, part of common generalknowledge, or otherwise constitutes prior art under the applicablestatutory provisions; or is known to be relevant to an attempt to solveany problem with which this specification is concerned.

SUMMARY OF THE INVENTION

Briefly, the present invention satisfies the need for improvedsemiconductor structures and methods of making the same, which allowfor, e.g., the integrity of fin structures to be better preserved duringsemiconductor fabrication. The present invention may address one or moreof the problems and deficiencies of the art discussed above. However, itis contemplated that the invention may prove useful in addressing otherproblems and deficiencies in a number of technical areas. Therefore, theclaimed invention should not necessarily be construed as limited toaddressing any of the particular problems or deficiencies discussedherein.

In one aspect, the invention provides a method of forming asemiconductor structure. The method includes:

-   -   providing an intermediate semiconductor structure which        includes:        -   a semiconductor substrate;        -   a fin having an extended gate (EG) oxide layer in contact            with at least a portion of the fin; and        -   a gate stack disposed over a portion of the fin;    -   forming a silicon nitride layer over portions of the fin that        are not located under the gate stack; and    -   after forming the silicon nitride layer, performing one or more        ion implantation steps on the intermediate semiconductor        structure.

In another aspect, the invention provides a method of forming asemiconductor structure which includes:

-   -   providing an intermediate semiconductor structure, which        includes:        -   a semiconductor substrate;        -   a fin having an EG oxide layer in contact with at least a            portion of the fin; and        -   a gate material disposed over the fin;    -   forming, over the fin and gate material of the intermediate        semiconductor structure, a gate stack hardmask which includes an        oxide layer;    -   forming a silicon nitride barrier layer on the oxide layer of        the gate stack hardmask;    -   performing one or more gate stack hardmask patterning steps;    -   removing the EG oxide layer from portions of the fin that are        not located under the gate; and    -   after removing the EG oxide layer from portions of the fin that        are not located under the gate, performing one or more ion        implantation steps.

Certain embodiments of the presently-disclosed semiconductor structuresand methods of forming semiconductor structures have several features,no single one of which is solely responsible for their desirableattributes. Without limiting the scope of these semiconductor structuresand methods of forming semiconductor structures as defined by the claimsthat follow, their more prominent features will now be discussedbriefly. After considering this discussion, and particularly afterreading the section of this specification entitled “Detailed Descriptionof the Invention,” one will understand how the features of the variousembodiments disclosed herein provide a number of advantages over thecurrent state of the art. These advantages may include, withoutlimitation, providing semiconductor structures and methods of formingthe same which may allow for improved fin integrity followingsemiconductor processing, and/or enabling a lower energy implant scheme.

These and other features and advantages of this invention will becomeapparent from the following detailed description of the various aspectsof the invention taken in conjunction with the appended claims and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will hereinafter be described in conjunction withthe following drawing figures, wherein like numerals denote likeelements, and:

FIG. 1 is an isometric schematic view of a FinFET structure available inthe prior art;

FIG. 2 illustrates, in cross section, a portion of a conventionalsemiconductor substrate available in the prior art including a siliconsubstrate, a silicon oxide layer overlying the silicon substrate, and asilicon-comprising material layer overlying the silicon oxide layer.

FIG. 3A depicts cross-sections of portions of a conventionalsemiconductor structure.

FIG. 3B depicts process steps that make up part of a conventional methodof forming a semiconductor structure.

FIG. 4 depicts a method of forming a semiconductor structure accordingto one embodiment of at least one aspect of the present invention.

FIG. 5 illustrates cross-sections of portions of a semiconductorstructure being fabricated according to one embodiment of the presentinvention.

FIG. 6 depicts two transmission electron microscopy (TEM) images showingfins of semiconductor structures pre-implant.

FIG. 7 depicts two sets of TEM images (SCL nFET and SRAM) showing finsemiconductor structures during conventional processing.

FIG. 8 depicts two sets of TEM images (SCL nFET and SRAM) showing finsemiconductor structures during processing according to an embodiment ofthe present invention.

FIG. 9 depicts a process for forming a semiconductor structure accordingto an embodiment of the present invention.

FIG. 10A depicts a scheme for forming the silicon nitride layeraccording to an embodiment of the invention.

FIG. 10B depicts a scheme which represents a conventional semiconductorfabrication process lacking use of a pre-implant silicon nitrideprotective layer.

FIG. 11 shows a representation of an intermediate semiconductorstructure during processing according to embodiments of the inventivemethod following an EG oxide removal step.

FIG. 12 shows a representation of an intermediate semiconductorstructure during processing according to embodiments of the inventivemethod following removal of the pre-implant silicon nitride layer.

FIG. 13 depicts process steps that make up part of a conventional methodof forming a semiconductor structure.

FIG. 14 depicts TEM images of fins made according to conventionalsemiconductor processing.

FIG. 15 depicts process steps according to an embodiment of the presentinvention, utilizing a silicon nitride barrier layer, which is depositedover an oxide layer of the gate stack.

FIG. 16 depicts TEM images showing fin semiconductor structures duringprocessing according to an embodiment of the present invention.

FIG. 17 shows a representation of an intermediate semiconductorstructure during processing according to embodiments of the inventivemethod.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present invention and certain features, advantages, anddetails thereof, are explained more fully below with reference to thenon-limiting embodiments illustrated in the accompanying drawings.Descriptions of well-known materials, fabrication tools, processingtechniques, etc., are omitted so as to not unnecessarily obscure theinvention in detail. It should be understood, however, that the detaileddescription and the specific examples, while indicating embodiments ofthe invention, are given by way of illustration only, and are not by wayof limitation. Various substitutions, modifications, additions and/orarrangements within the spirit and/or scope of the underlying inventiveconcepts will be apparent to those skilled in the art from thisdisclosure.

Reference is made below to the drawings, which are not necessarily drawnto scale for ease of understanding, wherein the same reference numbersused throughout different figures designate the same or similarcomponents.

FIG. 3A depicts cross-sections of portions of a conventionalsemiconductor structure. During implantation, the silicon fin 12 isamorphized, and during photoresist (PR) strip following implantation,fin material is lost which causes the fin critical dimension (CD) tothin down (E<C), external resistance (Rext) to increase and,consequently, device performance degradation. Further, the CD of polygate 30 (A) (depicted in the upper left of FIG. 3A under NiT gatehardmask 30), that receives implant is smaller than the final HK/MGmetal gate 38 CD (D), D>A+2*B, where B is the thickness of the SiO₂ EGoxide layer 18. The present invention provides semiconductor structuresand methods of making the same that address these and other problems anddeficiencies.

FIG. 3B shows steps that make up part of a conventional method offorming a semiconductor structure including fins 12. Also depicted areshallow trench isolation (STI) regions 32. The top illustration showsfins perpendicular to the screen, whereas the bottom illustration showsfins parallel to the screen.

Generally stated, disclosed herein are improved semiconductorstructures, including improved finFET structures, and methods of makingthe same.

FIG. 4 depicts a method of forming a semiconductor structure accordingto one aspect of the present invention. Referring to FIG. 4, the processincludes (in one embodiment): providing an intermediate semiconductorstructure having a fin with an EG oxide layer on at least portions ofit, and a gate stack disposed over a portion of the fin 100; forming asilicon nitride layer over portions of the fin that are not locatedunder the gate stack 110; and, after forming the silicon nitride layer,performing one or more ion implantation steps on the intermediatesemiconductor structure 120.

In various embodiments, the silicon nitride layer is formed over, e.g.,in direct contact with, the EG oxide layer of one or more fins. In someembodiments, the silicon nitride layer is formed using atomic layerdeposition (ALD).

In some embodiments, the inventive methods include, in addition to useof a pre-implant silicon nitride protective layer, any additionaldesired semiconductor fabrication steps. For example, such additionalsteps may include one or more of POR processing, recrystallization of,e.g., amorphous portions of the fin(s), and forming an epitaxial layeron at least a portion of the fin.

FIG. 5 illustrates cross-sections of portions of a semiconductorstructure, pre- and post-implant, being fabricated according to oneembodiment of the present invention. As shown, prior to implantation,portions of the fin 12 are coated with a thick oxide layer (which isreferred to herein as an “EG oxide layer”) 18, which, in the embodimentof FIG. 5, is a SiO₂ layer. A silicon nitride (SiN) layer 36 is formedover at least a portion of the EG oxide layer 18. In some embodiments,the silicon nitride layer 36 may be, for example, 0.5 nm to 4 nm thick,for example, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4.0 nm thick,including any and all ranges and subranges therein (e.g., 1 to 3 nm). Inthe depicted embodiment, the silicon nitride layer 36 is about 2.0 nmthick. In some embodiments, the silicon nitride layer 36 is formed aftera re-oxidation step.

Following formation of the silicon nitride layer 36, one or more ionimplantation steps are performed on the intermediate semiconductorstructure. In some embodiments, the one or more ion implantation stepsinclude a post-implant anneal.

In some embodiments of the invention, one or more PR strip steps mayfollow or form a part of the one or more ion implantation steps.

In certain embodiments of the invention, subsequent to the one or moreion implantation steps, the silicon nitride layer 36 is removed. Sincethe silicon nitride layer 36 becomes oxidized throughout the post-PCblock layer implantation process, this oxidized film can be removedbefore entering the S/D epitaxy modules. In some embodiments, this helpsto remove the oxide on the sidewalls of the of the polysilicon gate,which prevents PC blowout that would occur in the RMG module (an issuethat was seen in planar 20 nm technology).

In some embodiments, the silicon nitride layer 36 is removed after oneor more post-implant anneal steps.

In some embodiments, the inventive methods include removing the siliconnitride layer 36 with a wet and/or dry etch. For example, wet and dryetches (e.g., treatment with hydrofluoric (HF) acid or Siconi treatment)may be used to remove portions of the silicon nitride layer 36 thatbecome oxidized during semiconductor fabrication steps following thesilicon nitride layer formation. In certain embodiments (for example,where a particularly thick silicon nitride layer 36 is used), thestep(s) of removing the silicon nitride layer 36 may include one or moretreatments to remove one or more un-oxidized portions of the siliconnitride layer 36 (e.g., treatments using phosphoric acid). Thus, incertain embodiments, removing the silicon nitride layer 36 includes oneor more of a wet or dry etch, together with a treatment to removeun-oxidized portions of the silicon nitride layer 36.

The silicon nitride layer 36 used in the invention serves to, e.g.,protect the fin from amorphization during implant processing. As shownin FIG. 5, where the bottom portion of the figure represents asemiconductor structure post-implant, the final fin CD (E) is equal toor close to the pre-implant fin CD (C). Similarly, the final gate CD (D)is equal or close to the pre-implant gate CD (A).

FIG. 6 depicts two transmission electron microscopy (TEM) images showingfins of semiconductor structures pre-implant. As shown, the average fintip width for the SCL image is 10.3 nm, and the average fin tip widthfor the SRAM image is 11.9 nm. The fins shown in FIG. 6 have a thin (2-3nm) coating of EG oxide (SiO₂) on them.

FIG. 7 depicts two sets of TEM images (SCL nFET and SRAM) showing finsemiconductor structures during conventional processing, such as thatshown in FIG. 3B. The top row (SCL nFET) depicts images duringprocessing performed on the fins 12 shown in the SCL image of FIG. 6,while the bottom row (SRAM) depicts images during processing performedon the fins 12 shown in the SRAM image of FIG. 6. Referring to FIG. 7,the first column (“Pre-SP1”) provides TEM images of the fins shown inFIG. 6, after the FIG. 6 fins 12 were subjected to ion implantation andPR strip following the implant. As shown in the Pre-SP1 column,following ion implantation and PR strip, the fins 12 have beenconsiderably compromised. The fin tips are amorphized and have undergoneconsiderable CD loss.

Returning to FIG. 7, the second column (“Post-SP1”) provides TEM imagesof the fins 12 shown in the first column of FIG. 7 after conventionalPOR processing, which includes formation of the depicted silicon nitride(SiN) spacer layer 40, which is used to protect certain layers fromepitaxial growth. Since the POR processing included growth at about 630°C., some recrystallization can be seen in the fins 12 of the secondcolumn, as compared to the first column.

Returning to FIG. 7, the third column (“Post-LSA”) provides TEM imagesof the fins 12 shown in the second column of FIG. 7 following laserspike annealing (LSA) to re-crystallize the fins 12.

As can be seen between FIGS. 6 and 7 (see fins 12 after LSA step),conventional semiconductor structure processing for the post-PC blocklayers, which implant through the EG oxide on the fins 12, causes fin CDloss due to the mix of amorphized silicon and the PR strips.

FIG. 8 depicts two sets of TEM images (SCL nFET and SRAM) showing finsemiconductor structures during processing according to an embodiment ofthe present invention. The first column (“Pre-SP1”) provides TEM imagesof the fins 12 shown in FIG. 6, after a ˜2 nm thick layer of siliconnitride was deposited over the EG oxide layer of the fins 12 by ALD.Following ALD of the silicon nitride layer, the fins 12 were subjectedto ion implantation and PR strip following the implantation. Theresultant fins 12, following ion implantation and PR strip, are shown inthe Pre-SP1 column. As can be seen, use of the silicon nitride layerprior to implant, in accordance with the present invention, resulted inimproved fins following implant and PR strip. The average fin tip widthfor the SCL nFET decreased from 10.3 nm to 8.5 nm (as compared to adecrease to 5.55 nm in conventional processing without the siliconnitride layer), and the average fin tip width for the SRAM decreasedfrom 11.9 nm to 10.4 nm (as compared to a decrease to 9.4 nm inconventional processing).

As evidenced by the results shown in FIG. 8, certain embodiments of theinvention provide an advantage over conventional semiconductorfabrication methods in that, during processing, after implantation andPR strip, there is a fin tip CD loss of less than 25% (e.g., less than25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7,6, 5, 4, 3, 2, or 1%) as compared to the fin tip CD before the one ormore ion implantation steps and PR strip, where “fin tip CD loss” may becalculated as:

$\frac{\left( {{Pre}\text{-}{Implant}\mspace{14mu}{Fin}\mspace{14mu}{Tip}\mspace{14mu}{CD}} \right) - \left( {{Post}\text{-}{Implant}\mspace{14mu}{Fin}\mspace{14mu}{Tip}\mspace{14mu}{CD}} \right)}{\left( {{Pre}\text{-}{Implant}\mspace{14mu}{Fin}\mspace{14mu}{Tip}\mspace{14mu}{CD}} \right)} \times 100$

By way of example, for the SCL nFET fins 12 shown in FIG. 8, whose widthdecreased from 10.3 nm to 8.5 nm in the inventive process, the fin tipCD loss would be 17.5%, whereas for the SCL nFET fins shown in FIG. 7,whose width decreased from 10.3 nm to 5.55 nm in conventionalprocessing, the fin tip CD loss would be 46.1%. In conventionalprocessing, fin tip CD loss is typically greater than or equal to 30%.Fin tip CD loss may also be calculated following formation of the spacer(e.g., using the images shown in the Post-SP1 column), and/or followingrecrystallization (e.g., using the images shown in the Post-LSA column).

Comparison of the fins 12 shown in the semiconductor structures depictedin the first column of FIG. 8, processed according to embodiments of theinventive process utilizing a pre-implant protective silicon nitridelayer, with the fins 12 shown in the first column of FIG. 7, processedaccording to the conventional process without the silicon nitride layer,clearly shows that embodiments of the present inventive methodeffectively reduce fin CD loss and preserve the integrity of finstructures post-implant. By realizing, inter alia, improved fin erosionduring post gate block layers and improved Rext from the ext area,embodiments of the inventive processes and the resultant inventivesemiconductor structures are able to reduce capacitance overlap (Cov) toimprove the alternating current (AC) and direct current (DC) performanceof circuits, and allow for overall improved semiconductor deviceperformance.

Returning to FIG. 8, the second column (“Post-SP1”) provides, similar toFIG. 7, TEM images of the fins 12 shown in the first column of FIG. 8after conventional POR processing, which includes formation of thedepicted silicon nitride spacer layer (“SiN spacer”) 40, which is usedto protect certain layers from epitaxial growth.

Returning to FIG. 8, the third column (“Post-LSA”) provides, similar toFIG. 7, TEM images of the fins 12 shown in the second column of FIG. 8following LSA to re-crystallize the fins 12. During LSA, thermal energyfor annealing is provided by applying laser light to the surface of thewafer for very short time intervals, typically from several nanosecondsto several milliseconds. Heat energy from the laser light raises thetemperature of the wafer surface to very high temperatures forannealing. For example, some LSA processes raise the temperature of thewafer surface to in excess of 1000° C.

While the inventive examples shown in the embodiment of FIG. 8 use LSA,other embodiments of the inventive methods may include otherrecrystallization techniques to re-crystallize, e.g., amorphous portionsof the fins following implant. In some embodiments, recrystallizationmay proceed by solid phase epitaxy (SPE) utilizing, e.g., temperaturesof 700° C. to 1400° C. In other embodiments, flash lamp annealing (FLA)or rapid thermal annealing (RTA) may be used.

As in the example shown in FIG. 8, according to some embodiments of theinventive methods, the pre-implant silicon nitride layer is disposedover the EG oxide layer on the fin 12.

In some embodiments of the invention, the EG oxide layer is not removedprior to formation of the silicon nitride layer and the one or more ionimplantation steps.

In other embodiments of the invention, the EG oxide is removed fromportions of the fin before the silicon nitride layer is formed. FIG. 9depicts one such embodiment.

FIG. 9 depicts a process for forming a semiconductor structure accordingto an embodiment of the present invention. As can be seen by comparingFIG. 9 to FIG. 3B, which depicts a conventional process, the embodimentof FIG. 9 includes, prior to implantation, an EG oxide removal step,which removes EG oxide from portions of the fin 12 that are not underthe gate stack. As shown, in this embodiment, the silicon nitride layeris still formed (“Thin SiN Layer Deposition” step in FIG. 9) prior toimplant, such that it effectively replaces the EG oxide layer onportions of the fins not located under the gate stack.

Embodiments of the invention such as that depicted in FIG. 9 alsoadvantageously allow for the omission of the gate reoxidation step shownin the conventional processing of FIG. 3B. Thus, in some embodiments ofthe invention, a gate reoxidation step is absent between gate etchprocessing and ion implantation.

Returning to FIG. 9, the depicted embodiment includes, following the oneor more ion implantation steps (“Post-PC Implant Layers” in FIG. 9),removal of the pre-implant silicon nitride layer (“Oxidized SiN Removal”in FIG. 9). Removal of the silicon nitride layer is discussed above, andcan include, for example, wet and/or dry etching to remove oxidizedportions of the layer, as well as treatment (e.g., with phosphoric acid)to remove un-oxidized portions of the layer. Following removal of thesilicon nitride layer, any desired further processing steps may bepursued. For example, conventional processing may be resumed.

In some embodiments of the invention, the silicon nitride layer isformed on, in addition to portions of the fin(s), at least a portion ofthe gate stack. This process is included (but not shown) in the “ThinSiN Layer Deposition” process step of FIG. 9.

FIG. 10A depicts a scheme for forming the silicon nitride layeraccording to an embodiment of the invention. The scheme of FIG. 10Acorresponds to the “SiN Layer Deposition” process step of FIG. 9.

Returning to FIG. 10A, the depicted scheme is a blanket deposition ofALD silicon nitride done before the post-PC block implant layers tocover the cap oxide as well as the exposed fins. This protects the capoxide from the wet resist strips, as well as the fins that becomeamorphized after the implantation. FIG. 10A may be compared with FIG.10B, which depicts a scheme which represents a conventional processlacking use of a pre-implant silicon nitride protective layer. As shownin FIG. 10B, in conventional processing, wet resist strips in thepost-PC block implant layers erode the oxide on top of the gates, aswell as the amorphized Si fins. Embodiments of the present inventionavoid such drawbacks associated with conventional processing.

FIG. 11 shows a representation of the intermediate semiconductorstructure during processing according to embodiments of the inventivemethod following the “EG oxide removal step” in FIG. 9. As illustrated,the EG oxide is fully removed from the fins 12 in the open area (notunder PC). This is the optimal condition for implantation because itallows for the use of a lower energy implant scheme, which enhancessubsequent recrystallization processing.

FIG. 12 shows a representation of the intermediate semiconductorstructure during processing according to embodiments of the inventivemethod following the “Oxidized SiN Removal” step in FIG. 9. As shown,the oxidized silicon nitride layer is fully removed from the fins 12 inthe open area (not under PC). If necessary, steps to remove anyun-oxidized portions of the nitride layer may be taken as well. Completeremoval of the layer, as shown, is the optimal condition for entranceinto the S/D module and RMG module because it prevents PC blowout.

Removal of the non-conformal EG oxide and replacement with a conformalsilicon nitride layer in accordance with certain embodiments of theinvention advantageously improves the post-PC implantation scheme,allowing more uniform doping of the fins. The silicon nitride layer alsohelps to protect the gate HM oxide and lateral fin CD from the wetresist strips, hence decreasing the series resistance. Removal of thisoxidized silicon nitride layer helps to prevent PC blowout in thedownstream RMG module.

In certain embodiments, the invention provides a method of protectingactive fins and hardmask (HM) oxide on top of a gate from resist stripsseen in, e.g., post-PC block layers, which method includes removal of EGoxide after the CT layer and replacing the EG oxide with a pre-implantsilicon nitride conformal layer.

In certain embodiments, the inventive processes provide for more uniformdoping of fins because of the conformal layer on top of the fins, asopposed to the non-conformal EG oxide that has been conventionally used.Resultant decreases in series resistance by maintaining the lateral finCD are also achieved.

In another aspect, the invention provides a method of forming asemiconductor structure, which method includes:

-   -   providing an intermediate semiconductor structure, which        includes:        -   a semiconductor substrate;        -   a fin having an EG oxide layer in contact with at least a            portion of the fin; and        -   a gate material disposed over the fin;    -   forming, over the fin and gate material of the intermediate        semiconductor structure, a gate stack hardmask including an        oxide layer;    -   forming a silicon nitride barrier layer on the oxide layer of        the gate stack hardmask;    -   performing one or more gate stack hardmask patterning steps;    -   removing the EG oxide layer from portions of the fin that are        not located under the gate; and    -   subsequent to removing the EG oxide layer from portions of the        fin that are not located under the gate, performing one or more        ion implantation steps.

FIG. 13 depicts process steps that make up part of a conventional methodof forming a semiconductor structure. As depicted, the conventionalprocess includes, after gate patterning, one or more gate etch steps.These include, for example, prior to the post-PC implant layers, a stepof depositing about a 1 nm thick oxide coating over the intermediatesemiconductor structure in order to redeposit oxide that is lost duringhard mask patterning.

FIG. 14 depicts TEM images of fins 12 made according to conventionalsemiconductor processing, such as that shown in FIG. 13. The images areenlarged versions of the two TEM images shown in the “Post-LSA” columnof FIG. 7. Returning to FIG. 14, as can be seen, the fins 12, which wereprepared using conventional processing (including implanting through theEG oxide on the fins), underwent considerable amorphization, making itdifficult to recrystallize the silicon fins effectively, and causingdefectivity in the form of fin defects after recrystallization 42 (seeFIG. 7 as well).

FIG. 15 depicts process steps according to an embodiment of the presentinvention, utilizing a silicon nitride barrier layer (“SiN BarrierLayer”), which is deposited over an oxide layer (“SiOx” in FIG. 15) ofthe gate stack. The silicon nitride barrier layer is deposited duringgate stack hardmask deposition, and it remains on the gate stackfollowing hardmask patterning. The silicon nitride barrier layer servesto protect the oxide layer (“SiOx” in FIG. 15) over which it is formed.In the depicted process embodiment, the protective silicon nitridebarrier layer protects the underlying oxide layer of the gate stacksufficiently such that, following the gate etch, the re-oxidation stepshown in FIG. 13 may be skipped.

In the depicted embodiment, following the gate etch, a “CT Clean Step”is performed to remove excess oxide (EG oxide) from the fins. The cleanstep may be, e.g., a wet or dry etch, such as HF or Siconi treatment,for removing the EG oxide layer from portions of the fin that are notlocated under the gate stack. By forming the silicon nitride barrierlayer prior to removing the EG oxide layer from free portions of the fin(i.e., not the portions under the gate stack), the oxide layer in thegate is protected during the later step that removes the EG oxide. Byremoving the EG oxide layer from around the free portions of the fins,but not from under the gate stack, and by protecting the oxide layer inthe gate (“SiOx” in FIG. 15), embodiments of the invention all for useof lower implant energies, thereby avoiding fin defects that occur afterrecrystallization in conventional semiconductor processing schemes.

FIG. 16 depicts TEM images showing fin semiconductor structures duringprocessing according to an embodiment of the present invention,resulting from the process shown in FIG. 15 (including removal of EGoxide), and following ion implantation (1 keV implant, which is ⅕ of theimplant energy used for the fins shown in FIG. 14). Fin CD is completelyretained, and no fin stacking faults are detected, due to use of ⅕ ofthe implant energy of conventional processing.

FIG. 17 shows a representation of the intermediate semiconductorstructure during processing according to embodiments of the inventivemethod following the “CT Clean Step” in FIG. 15. As shown, the EG oxideis fully removed from the fins 12 in the open area (not under PC). Thisis the optimal condition for implantation because it allows for the useof a lower energy implant scheme, which enhances the recrystallizationprocess.

According to various embodiments of the invention, after the CT CleanStep, the method includes performing post-PC block layers (implantationlayers), e.g., one or more ion implantation steps.

By making it possible to use a lower energy implantation scheme, forexample less than or equal to ⅕ the energy of conventional processing,embodiments of the inventive method reduce the amount of fin defectivitypresent after fins are recrystallized, thereby improving deviceperformance by, e.g., reducing resistance and increasing the drivecurrent. Further, use of the nitride barrier layer prevents the gatehard mask oxide from being affected when removing the EG oxide.

In various embodiments, the invention includes semiconductor structuresmade according to the presently-disclosed methods of makingsemiconductor structures.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprise” (andany form of comprise, such as “comprises” and “comprising”), “have” (andany form of have, such as “has” and “having”), “include” (and any formof include, such as “includes” and “including”), and “contain” (and anyform contain, such as “contains” and “containing”) are open-endedlinking verbs. As a result, a method or device that “comprises”, “has”,“includes” or “contains” one or more steps or elements possesses thoseone or more steps or elements, but is not limited to possessing onlythose one or more steps or elements. Likewise, a step of a method or anelement of a device that “comprises”, “has”, “includes” or “contains”one or more features possesses those one or more features, but is notlimited to possessing only those one or more features. Furthermore, adevice or structure that is configured in a certain way is configured inat least that way, but may also be configured in ways that are notlisted.

As used herein, the terms “comprising” and “including” or grammaticalvariants thereof are to be taken as specifying the stated features,integers, steps or components but do not preclude the addition of one ormore additional features, integers, steps, components or groups thereof.This term encompasses the terms “consisting of” and “consistingessentially of”.

The phrase “consisting essentially of” or grammatical variants thereofwhen used herein are to be taken as specifying the stated features,integers, steps or components but do not preclude the addition of one ormore additional features, integers, steps, components or groups thereofbut only if the additional features, integers, steps, components orgroups thereof do not materially alter the basic and novelcharacteristics of the claimed composition, device or method.

Where one or more ranges are referred to throughout this specification,each range is intended to be a shorthand format for presentinginformation, where the range is understood to encompass each discretepoint within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have beendescribed and depicted herein, alternative aspects and embodiments maybe affected by those skilled in the art to accomplish the sameobjectives. Accordingly, this disclosure and the appended claims areintended to cover all such further and alternative aspects andembodiments as fall within the true spirit and scope of the invention.

The invention claimed is:
 1. A method of forming a semiconductorstructure comprising: providing an intermediate semiconductor structurecomprising: a semiconductor substrate; a fin having an extended gate(EG) oxide layer in contact with at least a portion of the fin; and agate stack disposed over a portion of the fin; forming a silicon nitridelayer over portions of the fin that are not located under the gatestack; after forming the silicon nitride layer, performing one or moreion implantation steps on the intermediate semiconductor structure; andafter the one or more ion implantation steps, removing the siliconnitride layer, wherein, after removing the silicon nitride layer, thereis a fin tip critical dimension (CD) loss of less than 15% as comparedto the fin tip CD before the one or more ion implantation steps.
 2. Themethod according to claim 1, wherein the silicon nitride layer isdisposed over the EG oxide layer on the fin.
 3. The method according toclaim 1, wherein the silicon nitride layer has a thickness of 1 nm to 3nm.
 4. The method according to claim 1, wherein atomic layer depositionis used to form the silicon nitride layer.
 5. The method according toclaim 1, wherein removing the silicon nitride layer comprises atreatment to remove an un-oxidized portion of the silicon nitride layer.6. The method according to claim 1, further comprising, after removingthe silicon nitride layer, forming an epitaxial layer on at least aportion of the fin.
 7. The method according to claim 1, wherein, afterremoving the silicon nitride layer, there is a fin tip CD loss of lessthan 5% as compared to the fin tip CD before the one or more ionimplantation steps.
 8. The method according to claim 1, comprising,prior to forming the silicon nitride layer, removing the EG oxide layerfrom portions of the fin that are not located under the gate stack. 9.The method according to claim 8, wherein the silicon nitride layer has athickness of 1 nm to 3 nm.
 10. The method according to claim 2, whereinremoving the silicon nitride layer comprises a treatment to remove anun-oxidized portion of the silicon nitride layer.
 11. The methodaccording to claim 2, further comprising, after removing the siliconnitride layer, forming an epitaxial layer on at least a portion of thefin.
 12. A semiconductor structure formed according to the method ofclaim
 1. 13. A semiconductor structure formed according to the method ofclaim
 8. 14. A semiconductor structure formed according to the method ofclaim 7.